Metal Movie Cap Shield on a budget **DONE!! FINAL PICS ON PAGE 4

you could in theory measure the disc from different angles at all the exact same diameter and it should cross on dead center.
 
It also helps (at least for me) to mark your center before doing any cutting of the lip off. I used the holes from the rope handles as reference points to draw a line from the outside corner of one cut-out to the outside corner of the opposite side, creating an "X"
 
It also helps (at least for me) to mark your center before doing any cutting of the lip off. I used the holes from the rope handles as reference points to draw a line from the outside corner of one cut-out to the outside corner of the opposite side, creating an "X"

Excellent point. I used my newly found center point, drilled a tiny hole and attached a string and marker. Then drew a line along the botton edge. When I trimmed off the lip, the center point was EXACT.
 
Excellent point. I used my newly found center point, drilled a tiny hole and attached a string and marker. Then drew a line along the botton edge. When I trimmed off the lip, the center point was EXACT.

instead of using a string, i find it very helpful to use a aluminum yard or meter stick. They are flexible enough to bend along the curvature of the shield, and you can drill small holes in them at what ever spacing you like that can hold a sharpie or other marker and it will give you consistent accurate circles.
 
Finally got around to working on this today...

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Still need to attach the star and touch up some paint, then clear coat it
 
Thanks! Couldn't have done it without this thread :thumbsup

As far as the star goes, what is best way to attach it?
 
Used a contact cement for the star and it seems to be holding up well.

Started on the brackets and leather straps today

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Just need to make some bigger rings to attach the last four straps to form the arm straps and pick up some buckles from Tandy on Monday.
 
This is just amazing. Now that I am done with teaching for the current school year, I get to start on my Civil War/Death of Cap costume. This shield will just bring everything together.
 
Once again I am impressed by the work put into a project.
The final result looks really good, and I really enjoyed looking at all the steps and reading how you did it.
I hope you are suitable proud of your work.

Now what I need is someone to make a good quality shield like this in the UK.
I would love to have one of these in my office at home.
 
Any advise on how to put a shine on the sled prior to painting? My is stripped and degreased, but it is very dull.

That's where the stripping pad comes into play. You really have to work it in that circular motion to bring out that "brushed" effect, and it also cleans up that dullness. Once you're finished with that, wipe it down really well with acetone to take off all the residue
 
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